Brick Manufacturing

Process
in Charaktala Brick Factory
Ashish Jajodia
Geet Suri
L/O/G/O Prahlad Agarwal
Sandip Goyal
Sasikiran Battepatti
Twinkle Jaithalia
Contents

Direct Materials Required

Processes

Financials

Types of kiln

Visual Guide
Direct Materials
• Clay
• Extracted from river side
• Extracted from ground in construction sites
• Extracted from unused agricultural land

• Coal
• Fine quality which contain high carbon

• Direct Labour
Process
Step 6
Step 1 Step 2 Step 3 Step 4 Step 5

Winning

Preparation

Shaping
Drying

Firing

Quality Control
Financials(1/3)
Variable Cost Fixed Cost

 The cost of soil/clay  Depreciation of dies

is Rs. 1000 for 200 and trolleys.
cubic foot. (including
transportation)  Depreciation of
grinding and coal
 Cost of per labor per crushing machine.
day is Rs. 225
 Depreciation of the
 Cost of a firing man is kiln.
Rs. 225 per batch of  Rent/lease of land.
bricks
 Salary of supervisor
 The cost of coal is and other
Rs. 3000 per batch of administrative staffs.
bricks
Financials(2/3)
• 1400 bricks are made from 200 cubic foot soil/clay

• In one day 2 labors can make 1000 green bricks

• One batch is of 3000 bricks

• In one day 4 firing men are required for firing

• Fresh bricks are sold at Rs 4200 – Rs 5700 per 1000

bricks depending upon the quality
Financials(3/3)
• Cost per 1000 bricks
• Rs. 715 for soil (Rs1000/1400)*1000
• Rs. 450 for 2 labors for making green bricks.
• Rs. 1000 for coal (Rs3000/ 3000)*1000
• Rs. 300 for firing crew ((Rs225*4)/3000)*1000
• Rs. 200 for shifting, assorting and arranging bricks.
– Total cost for 1000 bricks is Rs. 2665
• Gross profit
• Average Sales (Rs. 5100) – direct cost (Rs. 2665) =
Rs. 2435 per 1000 bricks
Types of kilns
• Clamp Kiln – ANCIENT TECHNOLOGY - 4,000 B.C.
The Most Commonly Used Kiln In The Developing World.
These Kilns Have A Devastating Impact Both On The
Environment And Workers.
• Tunnel Kiln - Invented Germany 1877
Most Common In Developed Countries, Since Their Invention
Tunnel Kilns Have Now Become Highly Automated.
• Bulls Trench – Invented England 1876
Commonly Used In India. It Has No Roof And Can Only Be
Used Outside The Monsoon Season.
• Vertical Shaft Kiln – Invented China 1958
Reasonably Fuel Efficient However The Kiln Is Limited Due To
A Low Throughput.
Bull’s Trench Kiln
Advantages Disadvantages

• More fuel efficiency • Production rigid to market

compared to periodic fluctuations
kilns
• Experienced firing crew
• Low initial investment
• Moveable chimneys have a
• High capacity short working life

• Less optimum firing conditions

Diagrammatic Process of Vertical Shaft Kiln
Visual Tour
 Moulding

Mixing of raw material Drying

 Mouth of the kiln
Dried bricks
Firing Process
The end of the
Finished bricks
process
Transport
Thank You!

L/O/G/O